Mestek TUBULAR INDOOR GAS-FIRED DUCT FURNACE, Installation Instructions And Service Manual

Page 1: ... property damage injury or death Read the installation operating and maintenance instructions thoroughly before installing or servicing this equipment Install operate and maintain unit in accordance with the manufacturer s instructions to avoid exposure to fuel substances or substances from incomplete combustion which can cause death or serious illness The state of California has determined that t...

Page 2: ...uct furnace may be installed on the downstream side of a cooling unit without need of a bypass duct The following terms are used throughout this manual in addition to ETL requirements to bring attention to the presence of potential hazards or to important information concerning the product Indicates an imminently hazardous situation which if not avoided will result in death serious injury or subst...

Page 3: ...individual per instructions in this manual Also follow procedures listed on the Gas Equipment Start up sheet located on the back cover of this manual Use only the fuel for which the heater is designed see rating plate Using LP gas in a heater that requires natural gas or vice versa will create the risk of gas leaks carbon monoxide poisoning and explosion Do not attempt to convert the heater for us...

Page 4: ...pth 32 7 32 7 32 7 33 5 33 5 33 5 33 5 831 831 831 851 851 851 851 F Flue Size Diameter 5 5 5 6 6 6 6 127 127 127 152 152 152 152 G Air Inlet Size Diameter 5 5 5 6 6 6 6 127 127 127 152 152 152 152 Gas Inlet Natural Gas inch 1 2 1 2 1 2 3 4 3 4 3 4 3 4 Gas Inlet LP Gas inch 1 2 1 2 1 2 3 4 3 4 3 4 3 4 Approximate Unit Weight lb 160 221 250 270 296 321 355 kg 73 100 113 122 134 146 161 Approximate ...

Page 5: ...tallations at elevations between 0 and 2 000 feet 610m For unit installations in U S A above 2 000 feet 610m the unit input must be field derated 4 for each 1 000 feet 305m above sea level refer to local codes or in absence of local codes refer to the latest edition of the National Fuel Gas Code ANSI Standard Z223 1 NFPA 54 For installations in Canada any references to deration at altitudes in exc...

Page 6: ... before starting the job The duct furnace must be installed on the positive pressure side of the air circulation blower AIRCRAFT HANGARS In aircraft hangars duct furnaces must be at least 10 feet 3 05m above the upper surface of wings or engine enclosures of the highest aircraft to be stored in the hangar and 8 feet 2 4m above the floor in shops offices and other sections of the hangar where aircr...

Page 7: ...OW The installation is to be adjusted to obtain an air throughput within the range specified on the appliance rating plate COMBUSTION INLET AIR VENTILATION Inlet Air From Another Room If the duct furnace is installed in a separate room or compartment provide two inlet air openings The size of each vent opening should be no less than one square inch 6 452 square centimeters of free area for each 10...

Page 8: ... clearances service accessibility clearances take precedence See Clearances section under Installation Make certain that the lifting methods used to lift the duct furnace are capable of supporting the weight of the heater during installation Failure to heed this warning may result in property damage or personal injury See Table 1 for unit weights Make certain that the structure to which the duct f...

Page 9: ...has been completed Connecting the unit before completing the pressure leak test may damage the unit gas valve and result in a fire hazard Do not rely on a shut off valve to isolate the unit while conducting gas pressure leak tests These valves may not be completely shut off exposing the gas valve to excessive pressure and damage PIPE SIZING To provide adequate gas pressure to the gas unit heater s...

Page 10: ...lution or other approved method Never use an open flame or severe personal injury or death may occur 1 Determine the required Cu Ft Hr by dividing the input by 1000 For SI Metric measurements Convert BTU Hr to kilowatts Multiply the units inputs kW by 0 0965 to determine Cu Meters Hr 2 FOR NATURAL GAS Select pipe size directly from the table 3 FOR PROPANE GAS Multiply the Cu Ft Hr value by 0 633 t...

Page 11: ...essure Natural Gas Propane Gas Heating Value 1 050 BTU Ft3 39 1 MJ m3 2 500 BTU Ft3 93 1 MJ m3 Manifold Pressure Single Stage Application inch WC kPa 3 5 0 87 10 0 2 49 Two Stage Application High Fire inch WC kPa 3 5 0 87 10 0 2 49 Two Stage Application Low Fire inch WC kPa 1 1 0 27 3 8 0 95 Modulating Application High Fire inch WC kPa 3 5 0 87 10 0 2 49 Modulating Application Low Fire inch WC kPa...

Page 12: ...AND LOCATION NOTICE The thermostat must be mounted on a vertical vibration free surface free from air currents and in accordance with the furnished instructions Mount the thermostat approximately 5 feet 1 5m above the floor in an area where it will be exposed to a free circulation of average temperature air Always refer to the thermostat instructions as well as the duct furnace wiring diagram and ...

Page 13: ...13 ELECTRICAL CONNECTIONS continued Figure 7d Tubular Duct Furnaces Equipped with Natural Gas or Propane LP Gas Single Stage ...

Page 14: ...14 ELECTRICAL CONNECTIONS continued Figure 7e Tubular Duct Furnaces Equipped with Natural Gas or Propane LP Gas Two Stage ...

Page 15: ...ble materials A minimum of 12 inch 305mm of straight pipe is required from the venter outlet before installing an elbow in the vent system An elbow should never be attached directly to the venter Never use a pipe of a diameter other than that specified in Table 1 Never use PVC or other nonmetallic pipe for venting To do so may result in serious damage to the unit severe personal injury or death An...

Page 16: ...djoining Building or parapet 10 feet 10 feet 3 04m Adjacent public walkways 7 feet above grade 7 feet 2 1m above grade Electric gas meters regulators 4 feet horizontal 3 feet 0 9m horizontally from meter regulator asembly 6 feet 1 8m any direction from a gas service regulator vent outlet Above grade level 1 foot 1 foot 0 3m Minimum above maximum snow depth or per local code whichever is greater AD...

Page 17: ...uct furnace at least 1 4 inch per foot 21mm m minimum Horizontal runs should not exceed 75 of the vertical height of the vent pipe or chimney above the flue pipe connections up to a maximum length of 10 feet 3m Horizontal portions of the venting system shall be supported at minimum intervals of 4 feet 1 2m in the United States and at minimum intervals of 3 feet 1m in Canada See Figure 8A 4 Use as ...

Page 18: ...material by flue gases Minimum and maximum wall thickness for the venting system consist of 4 1 4 inch 105mm to 8 1 2 inch 216mm for 5 inch 127mm diameter vent pipe and 5 3 4 inch 146mm to 11 1 2 inches 292mm on 6 inch 152mm vent pipe 5 Through the wall vent for these appliances shall NOT terminate over public walkways or over an area where the condensate or vapor could create a nuisance or hazard...

Page 19: ...horites Approved Vent Terminal 5 ft 1 52 m Min 1FT 305 mm Min above grade plus max snow depth or per local code whichever is greater 1 FT Min 305 mm 1 4 per foot Min Slope 21mm m 2 ft Min 0 61 m Min 5 ft Min 1 52 m Min 6 152 mm Min Distance from pipe to ceiling 10 ft Max 3 05 m Not to Exceed 75 Vertical Flue Height 1 4 per foot Min Slope 21 mm m Thimble Roof Use Insulated Stack Outdoors Approved V...

Page 20: ...wn combustion air system It MUST NOT be connected to other air intake systems 4 Use UL 1738 listed single wall pipe for the vent system For installations in Canada use UL S636 listed vent pipe conforming with local building codes or in the absence of local building codes with current CSA B149 1 Installation Codes for Natural Gas Burning Appliances and Equipment or CSA B149 2 Installation Codes for...

Page 21: ... in Table 1 Never use PVC ABS or any other non metallic pipe for venting To do so may result in serious damage to the unit and or severe personal injury or death 5 Any run of single wall vent pipe passing through an unheated space must be insulated with an insulation suitable to 550 F 288 C 6 The vent system must be installed to prevent collection of condensate Pitch horizontal pipes downward 1 4 ...

Page 22: ...Cleanout Cap Roof Flashing Breidert Type L or Fields Approved Terminal 10 ft 3 04m Min to Wall or Adjoining Building 2 ft 609m Min Plus Max Snow Depth for Area 3 ft 1m Min Plus Max Snow Depth 12 in Min 305 mm Exhaust Vent Combustion Air Inlet Combustion Air Exhaust Figure 9B Horizontal Inlet Vent Locations Separated Combustion D9380 CAT 2765C ...

Page 23: ...23 VENTING continued Figure 10A Vertical Arrangement Single Wall Vent System to Single Wall Termination Figure 10B Horizontal Arrangement Single Wall Vent System to Single Wall Termination D3620F D3619C ...

Page 24: ...24 VENTING continued Figure 11A Vertical Arrangement Single Wall Vent System to Double Wall Termination Figure 11B Horizontal Arrangement Single Wall Vent System to Double Wall Termination D3661F D3662D ...

Page 25: ...de energized 6 The wall thermostat supplied optionally is a temperature sensitive switch that operates the power vent and direct spark ignition system to control the temperature of the space being heated The thermostat must be mounted on a vertical vibration free surface free of air currents and in accordance with the furnished instructions also refer to Electrical Connections section of this manu...

Page 26: ...urnace If the duct furnace is equipped with a pressure regulator on the combination gas valve follow steps a through d above If the duct furnace is not so equipped the propane gas supply system pressure must be regulated to attain this manifold operating pressure OPERATION continued Table 7 Main Burner Orifice Schedule Standard Altitude TUBULAR DUCT FURNACE HIGH ALTITUDE DERATION This Tubular duct...

Page 27: ...5 68 Notes 1 Deration based on ANSI Z223 1 NFPA 54 2 Table based on heating value of 1 050 BTU Cu feet at sea level 3 Table based on heating value of 2 500 BTU Cu feet at sea level 4 Consult local utility for actual heating value High Altitude Deration Canada Altitude Manifold Pressure BTU Output 1 Natural Gas 2 Liquid Propane 3 Feet Meters Inches W C Pa Inches W C Pa Percentage 0 2 000 0 610 3 5 ...

Page 28: ... in this manual Under no circumstances should combustible material be located within the clearances specified in this manual Failure to provide proper clearance could result in personal injury or equipment damage from fire 2 Turn off the manual gas valve and electrical power to the duct furnace 3 Remove access panel 4 To clean or replace the burners a Disconnect the gas inlet pipe b Remove the fou...

Page 29: ...3 24 25 26 27 28 30 29 31 AIR FLOW 5 19 18 1 Vestibule panel tube assembly heat exchanger 2 Manifold 3 Manifold bracket sub assembly 4 Inshot burner 5 Burner orifice 6 Gas valve 7 Gas inlet pipe 8 Gas inlet grommet 9 Flame sensor 10 Spark ignitor 11 Control board 12 Transformer 13 Air pressure switch 14 Control sub panel 15 Terminal block plate 16 High limit switch 17 Flue collector 18 Flue collec...

Page 30: ...ction of this manual 1 Replace orifice 2 Test and reset manifold pressure see Gas Supply Pressure Table in the Pipe Installation section of this manual 1 Clean main burner ports 2 Replace manifold assembly 3 Refer to Installation Clearances and Venting sections in this manual to ensure unit is properly mounted and vented 4 Check gas input and manifold pressures 5 Check flue vent pipe and clear as ...

Page 31: ...te thermostat away from outside wall or drafts 2 Check thermostat circuit for open and close on heater terminal strip R and W 3 Check thermostat circuit for shorts or any staples piercing wires 4 If thermostat is calling after set point has been satisfied replace 5 Check for 24V on gas valve terminals when thermostat not calling Replace if necessary 6 Check for 24V at terminals R and W If not pres...

Page 32: ...at for operation to ensure circuit open and closes 3 Check wiring per diagram Check operation at the gas valve Look for a short in thermostat circuit 4 Replace valve and check pressure setting see Gas Supply Pressure Table in the Pipe Installation section of this manual 5 Refer to Gas Supply Pressure Table in the Pipe Installation section of this manual 6 See blower manufacturer for corrective act...

Page 33: ...ce switch 4 Check for 24V on line side of high limit Constant voltage should be recorded If not control board is suspect Check flash code 1 Turn on power supply check fuses and replace if bad 2 Turn up thermostat Check for 24V on terminals R and W1 on terminal strip 3 Check all wiring in the power vent circuit to ensure good connection including neutral 4 Check for 115V between motor leads and che...

Page 34: ...nnects pressure switch and draft inducer 3 Airflow switch jumpered or miswired 1 Open manual reset rollout switch 2 Gas pressure too high over fire condition 3 Incorrect airflow due to blockage or motor not operating 1 Flame probe miswired or shortened 1 Thermostat is interfering with control board Control OK no call for heat Control OK call for heat present Internal control fault or no power Cont...

Page 35: ... Type UT TD Tubular Duct Furnace 3 4 5 Capacity CA 100 100 000 BTU HR 150 150 000 BTU HR 200 200 000 BTU HR 250 250 000 BTU HR 300 300 000 BTU HR 350 350 000 BTU HR 400 400 000 BTU HR 6 Furnace Type FT A Left Side Access Note Field convertible to right side access refer to unit installation instructions 7 Heat Exchanger Furnace Material FM 1 Aluminized Steel Standard 2 409 Stainless Steel Note Hea...

Page 36: ...all field installed controls been installed Do you understand all the controls on this equipment If not contact your wholesaler or rep DO NOT START this equipment unless you fully understand the controls GAS EQUIPMENT START UP GENERAL With power and gas off Make certain all packing has been removed Tighten all electrical terminals and connections Check all controls for proper settings Remarks ____...